Cement resin hybrid paint and coating

ABSTRACT

A system for forming a coating on a substrate is provided. The system includes a first mix having a cement, a filler, a defoamer, a cement retarder, a dispersing agent, or any combination thereof. The system additionally includes a second mix having a fatty acid derivative, a synthetic resin, one or more organosilicon compounds, a pigment, a thickener, or any combination thereof. A coating composition is formed by mixing the first and second mix together. Lastly, the system includes a spraying apparatus that applies a wet film to the substrate wherein the cured coating does not yield to wet-rubs and does not stain (effloresce) with cold distilled water.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. Pat. No. 10,647,855, issued May12, 2020, entitled “CEMENT RESIN HYBRID PAINT AND COATING,” which claimsthe benefit of and priority to U.S. Provisional Patent Application No.62/479,626, filed on Mar. 31, 2017, entitled “CEMENT RESIN HYBRID PAINTAND COATING,” the entire disclosures of which are both herebyincorporated herein by reference.

FIELD OF THE INVENTION

The present invention generally relates to coatings for a variety ofsubstrates, and more specifically, a cement resin hybrid paint that maybe used as a specialized coating.

BACKGROUND OF THE INVENTION

The paint and coatings industry is one of the most heavily regulatedindustries in the world. This global paint and coatings market iscurrently estimated to produce nearly 9 billion gallons with NorthAmerica estimated at 1.5 billion gallons or 27.8 billion dollars. Thechallenges associated with this market include increased restrictions onvolatile organic compounds (VOCs), expanding interest in green buildingstandards, and current and future labor shortages within the trades.

Paints and other types of coatings are typically applied as liquids to awide variety of substrates. Such coatings can be applied for a varietyof reasons, for example, as protective coatings, decorative coatings,sealants, for insulation purposes, and/or to modify the surfacecharacteristics of a substrate.

Typically, paints and coatings applied as liquids comprise four primarycomponents: pigment; vehicle; additives; and solvent. Pigment is used torefer to coloring agents used for non-film forming components. Vehicleis used to refer to the materials used to form the film, for example,polymeric materials that can provide the protective and/or functionalcoating. Additives are used in coatings for one or more reasonsincluding aiding in manufacturing, enhancing applicationcharacteristics, or improving the properties of the coating once it isapplied. The solvent typically is a volatile material that functions asa dispersing medium for the pigment and the vehicle while serving as acarrier for transporting the solid materials onto the substrate. Oncethe coating has been applied, it is generally desirable to evaporate thesolvent to establish the vehicle as a film. For many coatings, theremoval of the solvent initiates the formation of the film as thesolvent evaporates into the atmosphere. In some instances, when thecarrier solvent is organic, it may be considered a volatile organiccompound (VOC) that may be governed by certain environmentalregulations.

Depending on the desired use, the solvent may cause a variety of issuesthat may be problematic to the application. For example, many coatingsand paints are formed from a suspension or solution where organicsolvents or carriers can create health and/or environmental issuesduring application. Upon evaporation of the solvent, the user may beexposed to carcinogenic materials. Aqueous carriers may also raisesolvent issues with respect to maintaining compositional integrityduring handling, storage, and application where aqueous carriers canexhibit greater sensitivity to environmental conditions such as weather,temperature, and humidity during their application.

Other issues found with the formulation and application of cementcoatings to a wide variety of substrates concern variable factors suchas: environmental conditions during application; drying time issues;coating thickness issues; application conditions; and logistical issues.Environmental conditions can relate to whether the coating is applied ina controlled interior environment or an exterior environment withvarious conditions. Coating thickness issues can relate to how thick thecoating application needs to be in order to be effective for theintended result or application. Application conditions relate to thetype of substrate the coating is applied to such as a vertical surfacewhere the wet film may sag or wash off the given substrate. Drying timeconditions can be strongly related to the weather where the coating isapplied in a humid or dry environment. The logistical issues can concernsuch factors as: whether specialized personnel or equipment are neededfor application; potential disruption of construction site processesduring application; selecting and waiting for appropriatetemperature/weather/environment conditions for application of thecoating and setup; and in some instances a need for tenting the regionto be coated in addition to using heaters for the tented region.

These and other issues are of concern when developing new cementcontaining coatings for use on particular substrates. Cement containingcoatings that are affordable, readily available, easily applied,resistant to efflorescence, and/or durable are desired by consumers andmust still be developed by producers.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a system for forming acoating on a substrate is provided. The system for forming a coating ona substrate includes a first mix having a cement, a filler, a defoamer,a cement retarder, a dispersing agent, or any combination thereof; asecond mix having a fatty acid derivative, a synthetic resin, anorganosilicon compound, a pigment, a thickener, or any combinationthereof; and a high throughput spraying apparatus that applies, by spraycoating, a coating composition to the substrate wherein the coatingcomposition is formed by mixing the first and second mix. The coatinghas no visible efflorescence and no water rub failure.

According to an aspect of the present disclosure, a system for forming acementitious coating on a substrate is provided. The system includes afirst mix including a cement and a filler, wherein the filler is atleast one material selected from a calcareous filler and siliceousfiller, and a second mix including a synthetic resin and a fatty acidderivative. The first mix and the second mix are adapted to be combinedto form a coating composition configured to be sprayed onto a substrateas a wet film configured to form a coating characterized by filmintegrity, as measured according to ASTM D5402, and no staining, asmeasured according to ASTM D1308, when applied at a wet film thicknessof 20 mils or less and dried at 25° C. and 50% relative humidity.

According to another aspect of the present invention, a hybridcementitious coating composition is provided. The hybrid cementitiouscoating composition includes a cement, a filler, a defoamer, a cementretarder, a dispersing agent, a fatty acid derivative, a syntheticresin, an organosilicon compound, a pigment, a thickener, or acombination thereof.

According to yet another aspect of the present invention, a method forapplying a hybrid cementitious paint coating having no visibleefflorescence on a substrate is provided. The method includes providinga dry mix having a cement, a filler, a defoamer, a cement retarder, adispersing agent, or a combination thereof; providing a wet mix having afatty acid derivative, a synthetic resin, an organosilicon compound, apigment, a thickener, or a combination thereof; mixing the dry mix withthe wet mix to form a coating composition; and spray coating the coatingcomposition using a high throughput spraying apparatus to form a wetfilm on the substrate. The high throughput spraying apparatus isselected from the group consisting of a high volume low pressure (HVLP)paint sprayer, air-assisted airless, and a piston-pump airless paintsprayer.

These and other features, advantages, and objects of the presentinvention will be further understood and appreciated by those skilled inthe art by reference to the following specification, claims, andappended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic flow diagram illustrating a system for forming acoating on a substrate;

FIG. 2 is a schematic flow diagram illustrating a method for applying ahybrid cementitious paint material to a substrate;

FIG. 3 is a chart referencing a series of compositions used todistinguish samples found in the prior art and the inventive coatingcomposition;

FIG. 4 is a chart referencing the results for an ASTM D5402 StandardPractice for Assessing the Solvent Resistance of Organic Coatings UsingSolvent Rubs and an ASTM D1308 Standard Test Method for Effect ofHousehold Chemicals on Clear and Pigmented Organic Finishes for theprior art and inventive coating compositions;

FIG. 5 is a reference picture of a sample that failed the ASTM D5402Standard Practice for Assessing the Solvent Resistance of OrganicCoatings Using Solvent Rubs;

FIG. 6 is a reference picture of a sample that failed the ASTM D1308Standard Test Method for Effect of Household Chemicals on Clear andPigmented Organic Finishes; and

FIG. 7 is a reference picture of a sample that passed both the ASTMD5402 Standard Practice for Assessing the Solvent Resistance of OrganicCoatings Using Solvent Rubs and the ASTM D1308 Standard Test Method forEffect of Household Chemicals on Clear and Pigmented Organic Finishes.

DETAILED DESCRIPTION

For purposes of description herein the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the device as oriented in FIG. 1. However, it isto be understood that the device may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

As used herein, the term “and/or,” when used in a list of two or moreitems, means that any one of the listed items can be employed by itself,or any combination of two or more of the listed items can be employed.For example, if a composition is described as containing components A,B, and/or C, the composition can contain A alone; B alone; C alone; Aand B in combination; A and C in combination; B and C in combination; orA, B, and C in combination.

In standard cement-based paints, Portland cement serves as the principalconstituent or vehicle and generally includes approximately 60%, byweight, of the composition. The cement may be blended with lime, up to25% by weight of the composition, along with an accelerator such ascalcium chloride, mineral fillers, and coloring agents to form a drypowder. When mixed with water in a given ratio by volume, the mixtureforms a slurry which may be applied in two or more coats over a varietyof surfaces. White cement is frequently combined with dolomite and waterto form a slurry to be applied as a primer coat to fill in open pores,cracks, and the like in a surface in order to reduce the consumption ofthe more expensive cement paint to obtain a complete, smooth, andfinished layer. Portland cement is chemically a complex mixture ofseveral compounds, mainly calcium silicates (with some aluminates),which react with water to form calcium silicate hydrate gels thatsolidify to produce an inorganic polymer under typical conditions.

Sufficient water is essential to the success of the Portland cementcuring process. While water loss can be a problem in a massive concretemix, the loss of water is somewhat limited and can be readily mitigated.When a cementitious material is applied as a thin film, however, theevaporation of water will generally occur too rapidly to allow forsufficient cement hydration. In arid environments, Portland cement-basedpaints will not cure properly at all, and even in temperate climates, itis necessary to constantly wet the films down, for many hours afterapplication. In spite of these difficulties, pigmented cement paintshave been marketed in some countries and used as cheap decorative flatwall paints for concrete, stucco, and masonry. When properly cured, thefilms can be hard and even durable, although they readily allow thetransmission of water and are generally used only for decorativepurposes. These corresponding cement paints can be quite inflexible anddo not have sufficient abrasion resistance for use on floors. Whenimproperly cured, they show poor durability and chalk readily outside.Since conventional cement paint powders are generally coarse in texturethey frequently do not adhere well to smooth plastered surfaces andconsequently require an application of a liquid cement primer to obtainproper adhesion or bonding on a smooth substrate.

A plurality of hybrid cementitious paint materials are disclosed hereinthat have about 50.00 weight % or less cement. These cementitious paintmaterials are considered hybrid in that they combine cement and one ormore synthetic resins, using a lower weight percent cement as comparedto other cementitious paint materials currently available on the market.In addition, these hybrid paints cure quickly to give robust and durablefilms/coatings which suffer neither discoloration nor coating failurewhen subjected to solvent rubs and have no visible efflorescence (waterstaining). The term “water rub” as used herein, is defined to refer toASTM D5402 Standard Practice for Assessing the Solvent Resistance ofOrganic Coatings Using Solvent Rubs as they cure, where distilled wateris the solvent. This ASTM D5402 test is employed to indicate the degreeof coating cure. The term “efflorescence” as used herein, is defined torefer to ASTM D1308 Standard Test Method for Effect of HouseholdChemicals on Clear and Pigmented Organic Finishes as they cure, wheredistilled water is the solvent. This ASTM D1308 test is employed toindicate the degree of staining of the coating.

Referring to FIGS. 1-7, a system for forming a coating on a substrate isprovided. The system includes a first mix 104 having a cement, a filler,a defoamer, a cement retarder, a dispersing agent, or any combinationthereof. The system additionally includes a second mix 108 having afatty acid derivative, a synthetic resin, an organosilicon compound, apigment, a thickener, or any combination thereof. Lastly, the systemincludes a high throughput spraying apparatus 116 that applies, by spraycoating, a wet film to the substrate by mixing the first and second mix104, 108 to form a coating composition 112 wherein the film has novisible efflorescence and no water rub failure.

Referring now to FIG. 1, a schematic flow diagram illustrating thesystem 100 for forming the coating on the substrate is provided. Thefirst mix 104 includes the cement, the filler, the defoamer, the cementretarder, and the dispersing agent. The second mix 108 includes thefatty acid derivative, the synthetic resin, the organosilicon compound,the pigment, and the thickener. The coating composition 112 is formed bymixing the first mix 104 and the second mix 108. The high throughputspraying apparatus 116 applies, by spray coating, the coatingcomposition 112 to the substrate. The coating composition 112 forms awet film on the substrate after the spray application where the wet filmwill cure and/or dry to form the coating on the substrate.

A. First Mix

The cement and other components of the first mix 104 may be combined ina fine particulate (fine particle or powder) form. In some embodiments,the first mix 104 is a dry mix where the cement, filler, defoamer,cement retarder, and dispersing agent components can be providedtogether in a solid or powdered form. The first mix 104 is then added asa solid to the second mix 108 to form the coating composition 112, or asa dry material to be dispersed in an aqueous liquid carrier of thesecond mix 108. However, in other embodiments, the first mix 104 may besuspended in a non-aqueous carrier fluid in order to rapidly distributeit with the second mix 108 to form the coating composition 112.Typically, when a liquid carrier is used for the first mix 104, theliquid carrier is chosen from non-aqueous materials that are eitherwater miscible or water-soluble to prevent cement curing.

The cement of the first mix 104 acts as a hydraulic binder that mayinclude, for example, a white or gray Portland cement in conformancewith ASTM C150, C595, C1157 or EN 197-1, a calcium aluminate cement inconformance with BS EN 14647 or BS 915-2, calcium sulphoaluminate cementor blends of Portland cement and one or more of calcium aluminate orcalcium sulphoaluminate cement. In some embodiments, the cement of thefirst mix 104 may include about 2.50 weight % to about 50.00 weight %,about 8.00 weight % to about 20.00 weight %, or about 8.00 weight % toabout 16.00 weight % of the coating composition 112.

The filler from the first mix 104 may include fine silica sand, quartz,talc, recycled glass, volcanic ash, perlite, fly ash, blast-furnaceslag, e-glass, metakaolin, calcium carbonate in the various forms foundin the industry (i.e., ground calcium carbonate, marble, calcite,limestone, and precipitated calcium carbonate), combinations thereof,and/or other fillers known to one skilled in the art. In someembodiments, the filler may be calcareous and/or siliceous particleshaving an average particle size less than about 425 microns. In someembodiments, the filler of the first mix 104 may include about 2.50weight % to about 50.00 weight %, about 25.00 weight % to about 48.00weight %, or about 36.00 weight % to about 46.00 weight % of the coatingcomposition 112. In some embodiments, the filler may alternatively oradditionally be used in the second mix 108.

The defoamer of the first mix 104 may include any suitable defoamerknown in the art, for example, a mixture of mineral oil and nonionicsurfactants either as a liquid product or as a powder product on aninert carrier, a defoamer based on fatty alcohol alkoxylates andpolysiloxanes either as a liquid or as a powder on an inorganic carriermaterial or mixtures thereof. In some embodiments, defoamer products maybe diluted to various degrees such that their neat dosage can be ordersof magnitude higher to achieve the desired defoamer actives. Whenreferring to the defoamer dosages disclosed in the embodiments herein,the defoamer dosages are based upon defoamer actives. In someembodiments, the defoamer of the first mix 104 may include about 0.001weight % to about 5.00 weight %, about 0.001 weight % to about 2.50weight %, about 0.001 weight % to about 1.00 weight %, about 0.01 weight% to about 0.50 weight %, or about 0.001 weight % to about 0.50 weight %of the coating composition 112. In some embodiments, the defoamer mayalternatively or additionally be used in the second mix 108.

The cement retarder of the first mix 104 may include citric acid andtartaric acid and their salts, gluconic acid and its salts, anionicand/or nonionic surfactants, zinc oxide, and/or other cement retardersknown to one skilled in the art. In some embodiments, the cementretarder of the first mix 104 may include about 0.01 weight % to about5.00 weight %, about 0.01 weight % to about 2.50 weight %, about 0.01weight % to about 1.00 weight %, or about 0.01 weight % to about 0.50weight % of the coating composition 112. In some embodiments, the cementretarder may alternatively or additionally be used in the second mix108.

The dispersing agent of the first mix 104 may include salts ofnaphthalene sulphonic acid formaldehyde condensates, salts of melaminesulphonic acid formaldehyde condensates, salts of lignosulphonic acidformaldehyde condensates, polycarboxylic acid, polysaccharides,polycarboxylate ethers, anionic surfactants, nonionic surfactants,and/or other dispersing agents known to one skilled in the art. In someembodiments, the dispersing agent of the first mix 104 may include about0.01 weight % to about 2.50 weight %, about 0.01 weight % to about 1.50weight %, or about 0.01 weight % to about 1.00 weight % of the coatingcomposition 112. In some embodiments, the dispersing agent mayalternatively or additionally be used in the second mix 108.

B. Second Mix

The components of the second mix 108 may be combined together with waterto form a wet mix in a liquid form. In some embodiments, the fatty acidderivative, synthetic resin, organosilicon compound, pigment, andthickener components of the second mix 108 or wet mix are providedtogether in a liquid form. The first mix 104 can be added as a solid tothe second mix 108 to form the coating composition 112 where the coatingcomposition 112 is a liquid. In some embodiments, the water of thesecond mix 108 may include about 1.00 weight % to about 35.00 weight %,about 2.50 weight % to about 25.00 weight %, or about 2.50 weight % toabout 15.00 weight % of the coating composition 112. The resultantcoating composition 112 retains free water which is made available forhydration of the cement and is self-priming even over smooth surfaces.

The fatty acid derivative of the second mix 108 may include carboxylicacid groups coupled to short chains (2-6 carbons), medium chains (6-12carbons), long chains (13-21 carbons), and/or very long chains (morethan 21 carbons). In some embodiments, some non-limiting examples offatty acid derivatives may include oleic acid, and/or stearic acid,and/or their salts such as calcium stearate, magnesium stearate,aluminum stearate, and zinc stearate. In some embodiments, the fattyacid derivative of the second mix 108 may include about 0.01 weight % toabout 10.00 weight %, about 0.01 weight % to about 7.50 weight %, about0.01 weight % to about 5.00 weight %, or about 1.00 weight % to about5.00 weight % of the coating composition 112. In some embodiments, thefatty acid derivative may alternatively or additionally be used in thefirst mix 104.

The synthetic resin dispersion or redispersible powder of the second mix108 may include, for example, acrylic co- and terpolymers, vinyl acetateco- and terpolymers including ethylene, vinyl versatate,2-ethylhexylacrylate, di-butyl maleate, vinyl chloride, epoxy resins,polyurethane dispersions, latex, and/or other synthetic resins known toone skilled in the art. The resin dispersions disclosed herein may varyin their solids content and adjustments for these resin solids can bemade and appreciated by those skilled in the art. In some embodiments,the synthetic resin of the second mix 108 may include about 5.00 weight% to about 75.00 weight %, about 10.00 weight % to about 50.00 weight %,or about 35.00 weight % to about 50.00 weight % of the coatingcomposition 112. In some embodiments, the synthetic resin dispersion orredispersible powder may alternatively or additionally be used in thefirst mix 104.

The organosilicon compound of the second mix 108 may include siloxanes,polysiloxanes, and one or more short chain (2-6 carbons), medium chain(6-12 carbons), long chain (13-21 carbons), and/or very long chain (morethan 21 carbons) alkyl or alkoxy silanes or combinations thereof. Forexample, in some embodiments, the organosilicon compound may includeglycidoxypropylmethyldiethoxysilane, n-octyl triethoxy silane,amino-functional silanes, vinyl-functional silanes, and/orpolyorganosiloxanes including methyl, ethyl, propyl, cyclohexyl, and/orphenyl groups. The liquid and powder organosilicon products commerciallyavailable to provide the organosilicon compound can vary in theirpercentage of organosilicon actives or relative amount of the actualorganosilicon compound. In the examples and embodiments provided herein,the weight percents are based on the relative amount of organosiliconactives. In some embodiments, the glycidoxypropylmethyldiethoxysilaneand n-octyl triethoxy silanes are used in combination at a respectiveratio of 3:1, 2:1, or 1:1. In some embodiments, the organosiliconcompound of the second mix 108 may include about 0.01 weight % to about10.00 weight %, about 0.01 weight % to about 5.00 weight %, or about0.10 weight % to about 0.50 weight % of the coating composition 112. Insome embodiments, the organosilicon compound may alternatively oradditionally be used in the first mix 104.

The thickener of the second mix 108 may include one or more of thefollowing: clays, including, for example, palygorskite, sepiolite,sodium or sodium exchanged montmorillonite, hectorite and/or organoclay;cellulose derivatives including, for example, methyl cellulose,carboxymethyl cellulose, methyl hydroxyethyl cellulose, methylhydroxypropyl cellulose, hydroxyethyl cellulose; hydroxypropylcellulose, starch ethers; galactomannans including, for example,hydroxypropyl guar and carboxymethylhydroxypropyl guar; microbialpolysaccharides such as xanthan gum, welan gum, diutan gum, andsuccinoglycan, carboxylated acrylic copolymer, and/or otherthickeners/polymeric thickeners known to one skilled in the art.Commercially available thickeners frequently come with the thickenerpredispersed in a continuous phase, e.g. water, so the examples providedherein are based on the respective weight of the thickener actives oractual thickener compounds. In some embodiments, the thickener of thesecond mix 108 may include about 0.001 weight % to about 2.50 weight %,about 0.001 weight % to about 1.00 weight %, or about 0.001 weight % toabout 0.50 weight % of the coating composition 112. In some embodiments,the thickener may alternatively or additionally be used in the first mix104.

The pigment of the second mix 108 may include pigment additives known inthe art. For example, in some embodiments, the pigment may include colorpigment additives including natural or synthetic iron oxides, cobaltaluminate, titanium dioxide, and carbon black pigments. Commerciallyavailable pigments frequently come with the pigment dispersed in acontinuous phase, e.g. water, so the examples provided herein are basedon the respective weight of the pigment actives or actual pigmentcompounds. In some embodiments, the pigment of the second mix 108 mayinclude about 0.01 weight % to about 5.00 weight %, about 0.01 weight %to about 2.00 weight %, or about 1.0 weight % to about 2.00 weight % ofthe coating composition 112. In some embodiments, the pigment mayalternatively or additionally be used in the first mix 104.

In some embodiments, a biocide agent or compound may be added to thefirst mix 104 and/or the second mix 108 to help stop or reduce thenegative effects caused due to microbial activities. The biocide of thefirst mix 104 and/or the second mix 108 may include1,2-benzisothiazol-3(2H)-one (BIT), ortho-phenyl phenol (OPP),alkylisothiazolinones such as octylisothiazolinone (OIT),3-iodo-2-propynyl-butylcarbamate (IPBC), carbendazim(2-benzimidazolecarbamic acid, methyl ester), chlorothalonil(1,3-dicyanotetrachlorobenzene), diuron(1,1-dimethyl-3-(3,4-dichlorophenyl)urea), azole-based antimicrobialssuch as tebuconazole(α-[2-(4-chlorophenyl)-ethyl]-α-(1,1-dimethylethyl)-1H-1,2,4-triazole-1-ethanol),propiconazole(1-[[2-(2,4-dichlorophenyl)-4-propyl-1,3-dioxolan-2-yl]methyl]-1H-1,2,4-triazole),and azaconazole(1-[[2-(2,4-dichlorophenyl)-1,3-dioxolan-2-yl]methyl]-1H-1,2,4-triazole),thiabendazole (2-(1,3-thiazol-4-yl)-1H-benzimidazole;2-(4′-thiazolyl)benzimidazole), zinc pyrithione,diiodomethyl-para-tolylsulfone, 2-(thiocyanomethylthio)benzthiazole,zinc dimethyldithiocarbamate, triclosan(2′,4′,4-trichloro-2-hydroxydiphenyl ether), cybutrin(2-(tert-butylamino)-4-(cyclopropylamino)-6-(methylthio)-1,3,5-triazine),terbutryn (2-ethylamino-4-methylthio-6-tert-butylamino-1,3,5-triazine),N-alkyl-substituted BIT such as N-butyl-BIT, dihalo-substitutedalkylisothiazolinones such as dichlorooctylisothiazolinone (DCOIT), andmixtures of two or more thereof. In some embodiments, the biocide agentof the first mix 104 and/or second mix 108 may include about 0.01 weight% to about 5.0 weight %, about 0.01 weight % to about 2.5 weight %,about 0.05 weight % to about 2.5 weight %, and about 0.05 weight % toabout 1.0 weight %.

C. Coating Composition

The hybrid cementitious paint materials includes both the dry mix/firstmix 104 including the cement, the filler, the defoamer, the cementretarder, and the dispersing agent used in combination with the secondmix 108 including the fatty acid derivative, the synthetic resin, theorganosilicon compound, the pigment, and the thickener. The coatingcomposition 112 (also referred to as the hybrid cementitious paintmaterial) is formed by combining/mixing the first mix 104 and the secondmix 108. Although the first mix 104 and second mix 108 are defined anddescribed in detail above, several of the components included in thefirst and second mixes 104, 108, as noted above, may be used in eitheror both mixes. In some aspects, some of the listed components may beused in both the first and second mixes 104, 108. The final cementitiouspaint coating products expected to be made commercially available arethe separately packaged first and second mixes 104, 108 in order toachieve longer shelf lives. In some embodiments, the coating composition112 may be pre-mixed and also made commercially available to consumers.

In some embodiments, the coating composition 112 includes the cement,the filler, the defoamer, the cement retarder, the dispersing agent, thefatty acid derivative, the synthetic resin, the organosilicon compound,the pigment, and the thickener. In some embodiments, the coatingcomposition 112 includes 8.0-20.0 weight % cement, 25.0-48.0 weight %fillers, 1.0-3.0 pigment, 0.5-3.0 weight % dispersing agent/cementretarder, 0.01-1.00 weight % defoamer, 0.01-1.00 weight % thickener,10.0-50.0 weight % synthetic resin, 0.01-5.00 weight % organosiliconcompound, 0.5-5.0 weight % fatty acid derivative, 0.05-2.50 weight %biocide, and 1.0-10.0 weight % water.

In other embodiments, the coating composition 112 includes 8.0-10.0weight % cement, 8-10 weight % recycled glass (filler), 1.0-3.0 weight %talc (filler), 25.0 to 30.0 weight % silica sand (filler), 1.0-3.0weight % iron oxide pigment (pigment), 3.0-5.0 weight % titania(pigment), 0.50-3.00 weight % wetting/dispersing agent (dispersing agentand cement retarder), 0.01-0.25 weight % defoamer, 0.01-0.25 weight %thickener, 40.0-45.0 weight % acrylic resin aqueous dispersion(synthetic resin), 1.0-3.0 weight % organosilicon compound, 0.75-3.0weight % fatty acid derivative, 0.05-1.0 weight % biocide, and 1.0-6.0weight % water.

The wet film formed by the application of the coating composition 112 tothe substrate eventually dries and forms the dried cementitious coating.The ability of these hybrid cementitious paints to cure quickly and formrobust films/coatings that can withstand the “water rub” and“efflorescence” tests are at least partly due to the ratio of selectivesynthetic resin/polymer to cement. In some embodiments, the weight ratioof synthetic resin solids to cement can be from 0.7 to 6.0, can be from0.9 to 6.0, or 1.0 to 3.0. In some embodiments, the ability of thesehybrid cementitious paints to cure quickly and form robustfilms/coatings that can withstand the “water rub” and “efflorescence”tests are at least partly due to the ratio of selective fatty acidderivative to cement. In some embodiments, the weight ratio of fattyacid to cement can be from 0.01 to 1.0, can be from 0.05 to 1.0, or from0.1 to 1.0.

For many latex paints, the small, spherical deformable particles oflatex approach each other until there is just enough water left to fillin the interstices between closely packed adjacent particles. Theresultant capillary forces tend to press these polymer particlestogether, and, if the ambient temperature is greater than the glasstransition temperature (T_(g)) of the polymer, the particles coalesce(fuse or merge into one another) to form a film. If the ambient andsurface temperatures are below the T_(g) of the polymer, the latexparticles will be too hard to deform and merge. Small amounts of highboiling solvents known as coalescing agents can be added during thepaint preparation stage to assist in this merging process. Coalescentsolvents are often employed to facilitate a harder polymer (one with ahigher T_(g) than substrate or ambient temperatures) in forming acontiguous film, where the coalescent solvent slowly evaporates overtime, resulting in a film with greater hardness and improved blockresistance. The reliance on evaporation as the sole means to build filmintegrity leaves latex paints susceptible to moisture in the substratewhich can compromise the adhesion of the coating to the aforementionedsubstrate. For very porous substrates, block-fillers are commonly usedwhich also rely on evaporation driven coalescence to achieve the desiredintegrity and as such have the same susceptibility to substrate moisturein addition to encountering difficulties in drying completely whenapplied thickly, hence providing a potential weakness for subsequentcoating failure.

The disclosed hybrid cementitious paint coating or coating composition112 uses a resin dispersion capable of film formation at a variety ofdifferent application temperatures without the need of a coalescentsolvent that can act as a source of VOCs and substances which may haveother grave health and environmental consequences. The coating formed bythe coating composition 112 is able to form with a faster integritywithout sacrificing a suitable pot-life time for the desiredapplication. In addition, the coating formed will not effloresce orchalk. The resultant coating formed by the coating composition 112 canreadily bond to smooth and/or porous substrates by filling voids whichcan eliminate the need for a separate block filler component. The hybridcementitious paint coating, unlike traditional cement paints, canadditionally provide protection against wind driven rain. The driedhybrid cementitious paint coating can readily be cleaned with a pressurewasher without the delamination observed in many latex paints. Thehybrid cementitious paint coating is able to continuously buildintegrity over time as a consequence of the cement content, resulting ina tough and durable coating.

D. Spraying Apparatus

The application of traditional cement-based paints can be laborintensive, usually being accomplished by brush or hopper sprayer,neither of which facilitate the timely completion of jobs requiring thecoverage of up to several thousand square feet. The desired thicknessesused in the application of these traditional materials require longerapplication times and lower coverage rates per gallon. The current lackof workers in the labor force only exacerbates this lack of productivityusing traditional cement-based paints.

In order to ensure formation of an effective coating for desiredapplications, it may be necessary to ensure that the substrate is wellcoated with the wet film of the coating composition 112, in spite ofvariations in the substrate surface, such as: cracks; rough surfacematerial variations; joints; and/or penetrations. In many applications,to obtain a sufficiently thick wet film to ensure proper coating in viewof the surface variations listed above, the coating composition 112 mayoften be applied as the wet film having a wet film thickness oftypically at least about 5 mils, and usually about 10 mils, sometimesabout 20 mils, about 30 mils, and in some instances at least 40 mils percoat, with a typical coating composition 112 thickness being from about5 mils to about 10 mils or from about 25 mils to about 125 mils (1mil=0.001 inch or 0.025 mm) per coat. In some embodiments, the thicknessof the wet film or wet film thickness is about 100 mils or about 200mils.

The high throughput spraying techniques described herein can be used toapply the disclosed coating compositions 112 to a very wide variety ofsubstrates. The high throughput spraying apparatus 116 can be applied inproviding coatings on substrates including, for example: masonry,cement, cement board, concrete (poured, cast, precast) wood, fiberboard, plaster, plaster board (gypsum board), metal, brick, paper,plastic, rubber, glass, asphalt and various foams and foam board (forexample polystyrene or polyurethane). For example, with respect tofoams, the coating composition 112 can be applied to expandedpolystyrene, polyurethane foam board with or without a variety ofpotential coatings known in the art. The substrate can be treated oruntreated, for example treated or untreated wood products, plywood,oriented strand board, gypsum sheathing, or board. The substrates canalso include treated materials, for example existing surfaces alreadyhaving a paint coating thereon. In some embodiments, the substrate canbe a metal or wood panel and/or deck. In some aspects, the substrate mayinclude pipes, cement, concrete, mortar, glass, metal, wood, drywall,paper, plastics, brick, clay, tile, stone, granite, marble, foam, foamboard, slate, terracotta, ceramics, paint, or combinations thereof.

In some embodiments, the substrate to which the coating composition 112is applied can be vertical (for example a wall) inverted (for example, aceiling) and/or horizontal (for example, a floor). A thick wet film maytend to distort under gravity, i.e. suffer sag, leading to distortionsor irregularities in the resulting film that are unacceptable. This isexacerbated by the fact that with a water-borne coating, and relativelyextended drying time, there is more opportunity for distortion, sag, orcoating damage. The disclosed compositions have a non-Newtonian rheologywith apparent yield stress values sufficient to reduce the likelihood ofdeformation due to sag.

When using relatively thick wet films, the act of drying and/orevaporating water and/or solvent from the coating composition 112 canitself raise issues. As the water and/or solvent is evaporated from thecoating composition 112 or wet film, the coating can become thinner andcan distort. The water and/or solvent evaporation can lead to blisters,puckering or other irregularities in the coating (film) leading to aloss of coating integrity. This issue is exacerbated with water-bornecoatings, as the coating thickness is increased, since such films dryfrom the outside in; in addition, the trapped water needs to escape aspart of the curing process. The disclosed coating compositions hereinare able to scavenge the aforementioned trapped moisture internallyeliminating the associated issues with water evaporation.

External to the coating composition 112, environmental conditions can bean important factor with water-borne coatings. The extensive dryingtimes required can mean that long breaks or stops in working arenecessary. Waiting for the right temperature and humidity circumstances,to provide proper and even drying (set up or cure) can create delay andexpense. Unanticipated weather patterns (temperature, precipitation,humidity) can result in an undesired resultant coating or film and/orthe need for multiple coating applications. The disclosed coatingcomposition 112 is capable of accelerated drying and re-coat times evenin high humidity, which would retard the evaporation induced filmformation of water-borne latex coatings. In some embodiments, thecoating composition 112 or wet film can dry in less than 8 hours, lessthan 7 hours, less than 6 hours, less than 5 hours, less than 4 hours,less than 3 hours, less than 2 hours, or less than 1 hour. In someexamples, the coating composition 112 or wet film can dry in less than 6hours.

The coating compositions 112 disclosed herein can be specificallyformulated for spray applications as described herein, where the mixedcoating composition 112 may remain stable for longer periods of timeprior to application, when compared to the prior art.

Upon contacting or mixing the first and second mixes 104, 108, thecoating composition 112 is formed. Although these first and second mixes104, 108 could be mixed as continuous flowing streams when the coatingcomposition 112 is applied to the substrate, the time after mixing,until application of the coating composition 112 on the substrate, isless than 3 hours. The coating composition 112 resulting from combiningthe first and second mixes 104, 108 will typically have an extended potlife. The term “pot life” as used herein, is defined to refer to thelength of time after combination of the first and second mixes 104, 108,until the combination can no longer be effectively applied, since it hasthickened too much. Typically, the pot life for the coating composition112 will be at least 8 hours. When spray coating the coating composition112, the pot life will be at least 1 hour, at least 2 hours, at least 3hours, at least 4 hours, at least 5 hours, at least 6 hours, at least 7hours, at least 8 hours, at least 9 hours, at least 10 hours, at least11 hours, or at least 12 hours. The pot life is determined bytemperature and relative humidity and can be modified with conventionalset modifiers as known to those skilled in the art. In some aspects, thehybrid cementitious coating composition 112 may be stored and appliedfor up to 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours,or 8 hours using a high throughput spraying apparatus selected from thegroup consisting of a high volume low pressure (HVLP) paint sprayer, apiston-pump airless paint sprayer, an air-assisted airless paintsprayer, and combinations thereof. Each of these referenced highthroughput spraying apparatuses are described in more detail below.

The film is applied to the substrate, by providing the coatingcomposition 112 as the wet film (thick or thin) on the substrate andallowing the film to set up (cure). When a 2-mix approach is used asdescribed herein, it is desired that the dry mix or first mix 104 bedirectly mixed with the wet mix or second mix 108 before the applicationoccurs, so that absorption of the free water by the dry mix/first mix104, from the wet mix/second mix 108, is initiated before the sprayapplication occurs. This system 100 or process does not require a rapidprocess of intimate mixing and application but rather can be mixed andstored for the duration of the respective pot life.

Conceptually, a variety of techniques for applying the coatingcomposition 112 as the wet film on the substrate can be used, forexample, brush application, spray application, roller application, etc.The particular application approach chosen may affect the choice ofmixing conditions and/or first mix 104 or second mix 108 compositions.The reason is that some applications lend themselves to very quickapplication after mixing while others require a more substantial potlife. In some embodiments, spray applications using the high throughputspraying apparatus 116 are used, since it can be conducted with a widevariety of time periods, and can be used to accomplish quick coatings ona large substrate. There is no specific requirement, other thanmanagement of issues concerning thickening and applicability, regardingthe technique of application.

The dry film thickness of the coating will be the thickness that resultsafter the wet film dries and the polymer resin and/or cement cures, forexample after the incorporation of the free water by the cement.Typically the wet film thickness is applied adequately to the substrateto provide that the resulting dry coating is appropriate to provide thedesired protective or other properties intended. In some embodiments,the application of the coating composition 112 to the substrate willyield a thickness of the resultant dried coating of at least about 2.5mils, at least about 10.5 mils, or at least about 15 mils per coatapplied. In additional embodiments, the thickness of the dried coatingwill be from about 5 mils to about 10 mils, about 15 mils to about 30mils, about 10 mils to about 100 mils, or about 10 mils to about 250mils per coat applied. The upper limit on the thickness can be increasedas needed by the application, so in some embodiments the thickness couldbe greater than 50 mils (1.25 mm), greater than 100 mils (2.5 mm), orgreater than 200 mils (5 mm).

The coating compositions 112 disclosed herein have the flexibility ofnot only remaining stable for extended periods of time but can also beapplied to substrates at a variety of temperatures. In some embodiments,the coating composition 112 can be applied under ambient conditions atabout 104° F. (40° C.). In other embodiments, the coating composition112 can be applied at colder temperatures such as about 50° F. (10° C.).In yet other embodiments, the coating composition 112 can be applied attemperatures between about 50° F. (10° C.) and about 104° F. (40° C.),between about 60° F. (15° C.) and about 95° F. (35° C.), and betweenabout 68° F. (20° C.) and about 86° F. (30° C.). The lower limit forthis application requires that the composition be a fluid when applied.Applying these coating compositions 112 at lower temperatures or higherhumidity conditions can be managed with the application of variouscomponents according to the present disclosure.

Handheld sprayers can utilize airless technology. A professionalpiston-pump design in a handheld sprayer gives painting contractors andconsumers the freedom to spray wherever they want with true airlessperformance. These handheld sprayers can be operated by electric orbattery power sources and are designed for small jobs and touchup work(1-3 gallons). The advantages of handheld sprayers are the professionalspray finish, ultimate portability on the job, and quick setup/cleanupcompared to using a larger airless sprayer for small jobs. Startup,spray, and cleanup can be done in minutes. The handheld sprayers aresimilar to a traditional airless sprayer where they have a gun and pumpbuilt into the sprayer. The only major difference is that a handheldsprayer does not have an airless hose, making it easier to start up.Without an airless hose, the handheld sprayer wastes less material andis also easy to clean for small jobs. There are several categories ofhandheld sprayers that are designed to spray specific materials.

There are two general types of pumps offered in the airless sprayermarket: diaphragm and piston. The advantages of a piston pump are: pumpshigher-viscosity coatings with ease, provides higher pressure at commontip sizes, better atomization, allows the use of longer hoses, betterwithstands hard use, lower maintenance costs, easy to repair, primeseasier, and runs only on demand. In some embodiments, a 2-ball pistonpump may be employed to spray the cementitious coatings describedherein. In embodiments when high volume low pressure (HVLP) sprayequipment is being used, the coating composition 112 is better appliedto the substrate using a pressure pot rather than by being gravity fed.

Equipment and techniques now known or developed in the future can beused for the mixing and the application of the coating composition 112as a spray. Equipment manufacturers and/or suppliers that can be usedare, for example, Coating Atomization Technologies, Louisville, Colo.80027; GRACO, Inc., Minneapolis, Minn. 55413; and Titan Tool, Plymouth,Minn. 55447. The equipment can be enhanced or modified for performance,depending upon the specific application intended.

Some non-limiting examples of HVLP sprayers are the C.A. TechnologiesLynx 100H, Panther 100H, and L200C. Representative properties of HVLPsystems used to apply the coating composition 112 include the HVLPhaving a fluid nozzle tip equal to or greater than 0.067-inch (1.7 mm)while in some embodiments the fluid nozzle tip is 0.110-inch (2.8 mm).The HVLP systems may additionally include a pressure pot rated to aminimum of 50 psi (0.3447 MPa) with an adjustable pot pressure and/or anadjustable gun inlet pressure. In other embodiments, some non-limitingexamples of airless sprayers are handheld piston pump sprayers such asthe Graco X-Force HD, and full size piston pump sprayers such as theGraco Ultra Max II 695, the Graco GMAX II 7900, or the Graco Mark V, gashydraulic airless sprayers such as GH130, GH200, and GH230 availablefrom Graco, Inc. of Minneapolis, Minn. Such equipment has the ability todeliver the coating composition 112 to a spray-gun at a pressuresufficient to atomize the liquid through an airless pumping system, andultimately, to the substrate. Representative properties of airlessspraying systems used to apply the coating composition 112 includehaving a maximum flow rate of greater than or equal to 0.9 gallons perminute (3.407 liter per minute). The airless sprayers may include theability to support spray tips of “0.017-inch (0.4318 mm) or largerand/or “0.021-inch (0.5334 mm) or larger and an operating pressure rangeof greater than or equal to 2000 psi (13.79 MPa). Air-assisted airlesssprayers combine an airless pump with pressurized air to effectatomization and fan control at the tip. Some non-limiting examples ofair-assisted airless sprayers include the Graco FinishPro II 395 PC andFinishPro II 595. Representative properties of air-assisted airlesssprayers include the ability to support spray tips of 0.017-inch (0.4318mm) or larger and/or 0.021-inch (0.5334 mm) or larger. Gas hydraulic,gas, and/or electric sprayers may additionally be used as highthroughput spraying apparatus as long as they are able to apply thecoating composition 112 without becoming clogged. The application of thecoating composition 112 using the piston pump airless sprayer system asdescribed herein rapidly, effectively, and evenly applied the wet filmwhere the application did not lead to cleaning issues or depositions inthe pump manifold, fluid lines, and/or spray gun assembly. As notedherein, piston pump airless sprayers and the other spraying apparatusesdisclosed herein are capable of applying a desirable wet film of thecoating composition 112 in an efficient commercial application whereapplication speed, drying times, application times, evenness of theapplied wet films, and reuse of high throughput sprayer devices aredesired.

In some embodiments, the high throughput spraying devices mentionedherein, including the hvlp sprayer, the piston-pump airless sprayer andair-assisted airless sprayer, may have a maximum flow rate of greaterthan or equal to 0.1 gallons per minute (gpm), greater than or equal to0.25 gpm, greater than or equal to 0.5 gpm, greater than or equal to0.75 gpm, greater than or equal to 1.0 gpm, or greater than or equal to1.25 gpm.

In a typical static mixer, two separate streams are brought together inthe mixer spray head, and are mixed with continuous streaming, as thespraying occurs. The intimate mixing that occurs in the spray head orequipment, combined with a rapid rate at which evacuation of the mixturefrom the spray head occurs, can provide for desirable effects dependingon the applied composition and application. Although the embodimentsdisclosed herein could potentially be used with a static mixer, thecoating compositions 112 are designed to be mixed before sprayapplication and then applied using the high throughput sprayingapparatus.

Referring now to FIG. 2, a method 200 for applying the hybridcementitious paint coating having no visible efflorescence on thesubstrate is provided. The method 200 includes providing the first ordry mix 104 including the cement, the filler, the defoamer, the cementretarder, and the dispersing agent (step 204). The method 200 alsoincludes providing the second or wet mix 108 comprising the fatty acidderivative, the synthetic resin, the organosilicon compound, thepigment, and the thickener (step 208). The dry mix can then be combinedor mixed with the wet mix to form the coating composition 112 (step212). The coating composition 112 can be spray coated using a highthroughput spraying apparatus to form a wet film on the substrate (step216). The high throughput spraying apparatus is selected from the groupconsisting of a high volume low pressure (HVLP) paint sprayer, anair-assisted airless sprayer, and/or a piston-pump airless paintsprayer. The wet film is then dried to form the hybrid cementitiouspaint coating on the substrate (step 220).

It is understood that the descriptions outlining and teaching the systemfor forming a coating on the substrate previously discussed, which canbe used in any combination, apply equally well to the method 200, whereapplicable, further disclosing the application of the hybridcementitious paint coating having no visible efflorescence on thesubstrate.

The development of this inventive hybrid cementitious coating and itsability to be spray coated reduces the labor required to prepare andapply the coating, reduces the amount of material (coating composition112) needed to complete a project, reduces the VOC content whileproviding a tough and durable finish. This inventive hybrid cementitiouscoating provides a sprayable architectural cement and resin coatingcomposition 112 that forms films that deliver a tougher, stronger, moredurable finish for concrete, block, and brick surfaces laden withfeatures including: low VOC while potentially contributing toward LEEDcertification, UV resistance and color stability based on iron oxidepigments, post-consumer glass content providing green characteristics,self-primer, efflorescence control, breathable finish allowing buildingto breath, wind driven results exceeding industry standards, uniquetextural finish, and the ability to coat new concrete faster thantraditionally known and used paints and coatings.

It will be understood by one having ordinary skill in the art thatconstruction of the described device and other components may not belimited to any specific material. Other exemplary embodiments of thedevice disclosed herein may be formed from a wide variety of materials,unless described otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components directly or indirectly to one another. Such joining maybe stationary in nature or movable in nature. Such joining may beachieved with the two components and any additional intermediate membersbeing integrally formed as a single unitary body with one another orwith the two components. Such joining may be permanent in nature or maybe removable or releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the spray devices as described herein are illustrativeonly. Although only a few embodiments of the present innovations havebeen described in detail in this disclosure, those skilled in the artwho review this disclosure will readily appreciate that manymodifications are possible (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connectors or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present device. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present device, and further it is to be understoodthat such concepts are intended to be covered by the following claimsunless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodimentsonly. Modifications of the device will occur to those skilled in the artand to those who make or use the device. Therefore, it is understoodthat the embodiments shown in the drawings and described above aremerely for illustrative purposes and not intended to limit the scope ofthe device, which is defined by the following claims as interpretedaccording to the principles of patent law, including the Doctrine ofEquivalents.

LISTING OF NON-LIMITING EMBODIMENTS

Embodiment A is a system for forming a cementitious coating on asubstrate. The system of Embodiment A includes a first mix comprising acement, a filler, a defoamer, a cement retarder, and a dispersing agent,a second mix comprising a fatty acid derivative, a synthetic resin, anorganosilicon compound, a pigment, and a thickener, and a highthroughput spraying apparatus that applies, by spray coating, a coatingcomposition to the substrate wherein the coating composition is formedby mixing the first and second mix. The coating has no visibleefflorescence and no water rub failure

The system of Embodiment A wherein the substrate comprises pipes,cement, concrete, mortar, glass, metal, wood, drywall, paper, plastics,brick, clay, tile, stone, granite, marble, foam, foam board, slate,terracotta, ceramics, paint, or combinations thereof.

The system of Embodiment A or Embodiment A with any of the interveningfeatures wherein the high throughput spraying apparatus comprises a highvolume low pressure (HVLP) paint sprayer.

The system of Embodiment A or Embodiment A with any of the interveningfeatures wherein the high throughout spraying apparatus comprises anair-assisted airless paint sprayer.

The system of Embodiment A or Embodiment A with any of the interveningfeatures wherein the high throughput spraying apparatus comprises apiston-pump airless paint sprayer.

The system of Embodiment A or Embodiment A with any of the interveningfeatures wherein the first mix comprises 2.50 weight % to 50.00 weight %cement, 25.00 weight % to 50.00 weight % filler, 0.01 weight % to 0.50weight % defoamer, 0.01 weight % to 0.50 weight % cement retarder, and0.01 weight % to 1.00 weight % dispersing agent of the coatingcomposition.

The system of Embodiment A or Embodiment A with any of the interveningfeatures wherein the second mix comprises 0.05 weight % to 5.00 weight %fatty acid derivative, 20.0 weight % to 50.0 weight % synthetic resin,0.01 weight % to 5.00 weight % organosilicon compound, 0.01 weight % to2.00 weight % pigment, and 0.01 weight % to 0.50 weight % thickener ofthe coating composition.

The system of Embodiment A or Embodiment A with any of the interveningfeatures wherein the filler comprises recycled glass, calcium carbonate,talc, precipitated amorphous silica, silica sand, or a combinationthereof.

Embodiment B is a hybrid cementitious coating composition including acement, a filler, a defoamer, a cement retarder, a dispersing agent, afatty acid derivative, a synthetic resin, an organosilicon compound, apigment, and a thickener.

The material of Embodiment B wherein the coating composition comprises2.50 weight % to 50.00 weight % cement, 25.0 weight % to 50.00 weight %filler, 0.01 weight % to 0.50 weight % defoamer, 0.01 weight % to 0.50weight % cement retarder, and 0.01 weight % to 1.00 weight % dispersingagent of the coating composition.

The material of Embodiment B or Embodiment B with any of the interveningfeatures wherein the coating composition comprises 0.05 weight % to 5.00weight % fatty acid derivative, 20.0 weight % to 50.0 weight % syntheticresin, 0.01 weight % to 5.00 weight % organosilicon compound, 0.01weight % to 2.00 weight % pigment, and 0.01 weight % to 0.50 weight %thickener of the coating composition.

The material of Embodiment B or Embodiment B with any of the interveningfeatures wherein the coating composition comprises 9.0 weight % to 20.00weight % cement, 38.0 weight % to 46.00 weight % filler, 0.01 weight %to 0.50 weight % defoamer 0.01 weight % to 0.50 weight % firstthickener, 0.01 weight % to 0.50 weight % cement retarder, and 0.01weight % to 1.00 weight % dispersing agent of the coating composition.

The material of Embodiment B or Embodiment B with any of the interveningfeatures wherein the coating composition comprises 1.0% to 5.0% fattyacid derivative, 35.0% to 50.0% synthetic resin, 0.01% to 5.00%organosilicon compound, 0.01% to 2.00% pigment, and 0.01% to 0.20%thickener of the coating composition.

The material of Embodiment B or Embodiment B with any of the interveningfeatures wherein the filler comprises recycled glass, calcium carbonate,talc, precipitated amorphous silica, silica sand, or a combinationthereof.

The material of Embodiment B or Embodiment B with any of the interveningfeatures wherein the hybrid cementitious coating composition is storedand applied using a high throughput spraying apparatus selected from thegroup consisting of a high volume low pressure (HVLP) paint sprayer, apiston-pump airless paint sprayer, an air-assisted airless paintsprayer, and combinations thereof.

The material of Embodiment B or Embodiment B with any of the interveningfeatures wherein the hybrid cementitious coating composition is appliedusing a high volume low pressure (HVLP) paint sprayer for up to 8 hours.

The material of Embodiment B or Embodiment B with any of the interveningfeatures wherein the hybrid cementitious coating composition is appliedusing a piston-pump airless paint sprayer for up to 8 hours.

The material of Embodiment B or Embodiment B with any of the interveningfeatures wherein the hybrid cementitious coating composition is appliedusing an air-assisted airless paint sprayer for up to 8 hours.

Embodiment C is a method for applying a hybrid cementitious paintcoating having no visible efflorescence on a substrate. The methodincludes providing a dry mix comprising a cement, a filler, a defoamer,a cement retarder, and a dispersing agent, providing a wet mixcomprising a fatty acid derivative, a synthetic resin, an organosiliconcompound, a pigment, and a thickener, mixing the dry mix with the wetmix to form a coating composition, and spray coating the coatingcomposition using a high throughput spraying apparatus to form a wetfilm on the substrate. The high throughput spraying apparatus isselected from the group consisting of a high volume low pressure (HVLP)paint sprayer, an air-assisted airless paint sprayer, and a piston-pumpairless paint sprayer.

The method of Embodiment C wherein the substrate comprises pipes,cement, concrete, mortar, glass, metal, wood, drywall, paper, plastics,brick, clay, tile, stone, granite, marble, foam, foam board, slate,terracotta, ceramics, paint, and combinations thereof.

The method of Embodiment C or Embodiment C with any of the interveningfeatures wherein the dry mix comprises 2.50 weight % to 50.00 weight %cement, 2.50 weight % to 50.00 weight % filler, 0.01 weight % to 0.50weight % defoamer, 0.01 weight % to 0.50 weight % cement retarder, and0.01 weight % to 1.00 weight % dispersing agent of the coatingcomposition.

The method of Embodiment C or Embodiment C with any of the interveningfeatures wherein the wet mix comprises 0.05 weight % to 5.00 weight %fatty acid derivative, 10.0 weight % to 50.0 weight % synthetic resin,0.01 weight % to 5.00 weight % organosilicon compound, 0.01 weight % to2.00 weight % pigment, and 0.01 weight % to 0.20 weight % thickener ofthe coating composition.

The method of Embodiment C or Embodiment C with any of the interveningfeatures wherein the filler comprises recycled glass, calcium carbonate,talc, precipitated amorphous silica, silica sand, or a combinationthereof.

EXAMPLES

Materials

The Portland Type I cement, recycled glass, calcium carbonate, talc,precipitated amorphous silica, metakaolin, silica sand, iron oxidepigment, titania, defoamer, wetting/dispersing agent, thickener, vinylresin redispersible powder, acrylic resin aqueous dispersion,functionalized silanes, and fatty acid derivatives were all obtainedfrom commercial suppliers and used as provided.

Methods and Procedures

First mix (dry mix): Pre-blend dry powder components.

Second mix (wet mix): Pre-blend wet liquid components where applicable.

Surface Preparation

The coating composition 112 should be applied to a clean surface of thesubstrate. The surface of the substrate to be painted should be freefrom oil, wax, concrete curing agents and bond breakers, chalk,efflorescence, mildew, rust, product fines, dust, or any other surfacecontaminants that could affect the performance of the hybridcementitious paint coating. Any loose, pealing, or cracking paintpresent should be removed by scraping, sanding, power washing, wirebrush, electric sanders or grinders, or by whatever means deemed asnecessary. Severely damaged areas may be repaired by tuck pointingand/or caulking all open seams. Glossy, rough, and patched surfaces maybe sanded. Areas affected by mildew should be treated with a commercialmildew remover. New concrete and masonry should be allowed to cure/dryfor at least 7 days before applying the coating composition 112.

The substrate should be tested for coating acceptability prior toapplication of the coating composition 112. This can be done by sprayingthe substrate with water. If the water soaks into the substrate, thesubstrate is properly prepared and can be coated when dry. If the waterbeads up and is repelled, the substrate may require additional cleaningprior to application of the coating.

Mixing

The coating composition 112 is a two-part mixture including the firstmix 104 (dry mix) and the second mix 108 (wet mix). The first mix 104(dry mix) and the second mix 108 (wet mix) can be combined and mixed onsite. In the Comparative Examples and Examples described below, themixer used was an EIBENSTOCK EZR 22 R R/L SET. The EIBENSTOCK “Special”mixer paddles were used with the EIBENSTOCK mixing stand. In theprovided Comparative Examples and Examples, a clean and empty 5-gallonpail was filled % full of water and the pail was placed in the area ofthe mixing stand. The lid was removed from the wet mix and the pailcontaining the wet mix was placed onto the mixing stand and the mixerpositioned into the pail. The mixing was started in the counterclockwisesetting (dashed arrow) for the wet mix on speed A. Slowly and carefully,the dry mix was added to the wet mix over about 5 minutes. The speed wasslowly increased by changing the mixer speed to setting ELF. After 1minute, the mixer was turned off, the sides of the pail were scraped,and the pail containing the coating composition 112 was carefullyrotated a half-turn (180°) and the sides were scraped again. The mixerwas turned back on and gradually returned to mixer speed ELF for 2 moreminutes. After the product was uniformly and completely mixed, the mixerwas returned to speed A, and then stopped. The mixer was transferredfrom the coating composition 112 to the pail of clean water. The mixerwas turned on for 10-20 seconds in clean water to remove coatingcomposition 112 from the paddles.

Application

The Comparative Examples and Examples described below applied thecoating composition 112 to the substrate where the wet film was allowedto dry at about 25° C. and 50% relative humidity. The coatingcomposition 112 was applied using either a high volume low pressure(HVLP) sprayer or a drawdown bar to yield a wet film thickness of about5 mils. As discussed herein, the wet film thickness can be varied usingan HVLP sprayer, drawdown bar, or other techniques depending on thedesired application.

ASTM Methods

ASTM D5402 Standard Practice for Assessing the Solvent Resistance ofOrganic Coatings Using Solvent Rubs. The solvent employed was distilledwater.

ASTM D1308 Standard Test Method for Effect of Household Chemicals onClear and Pigmented Organic Finishes. The solvent employed was colddistilled water.

Comparative Example 1

The dry mix used in Comparative Example 1 included 13.34 weight %Portland Type I Cement, 50.70 weight % recycled glass, and 4.00 weight %vinyl resin redispersible powder. The wet mix of Comparative Example 1included 0.02 weight % wetting/dispersing agent, 0.01 weight %thickener, and 31.93 weight % water. The given weight percentages areprovided with respect to the total weight of the combined coatingcomposition.

The film produced using the coating composition of Comparative Example 1also did not develop film integrity at 25° C. and 50% relative humiditywhen cured for more than 52 weeks. This deficiency is likely due to theloss of free water before sufficient curing (cement hydration) of thecoating composition. As expected, reactive coatings become moreresistant to solvents as they cure. ASTM D5402 was employed in thisexample to indicate the degree of cure. The coating made withComparative Example 1 additionally showed staining (efflorescence) withcold distilled water. ASTM D1308 was employed to illustrate whether ornot the coating was susceptible to induced efflorescence, which is ofgreat significance when applying the coating for decorative purposes,particularly if the coating were to encounter water in the form ofmoisture condensation, precipitation, or incidental contact like thatfrom irrigation.

Comparative Example 2

The dry mix used in Comparative Example 2 included 26.58 weight %Portland Type I Cement and 37.94 weight % silica sand. The wet mix ofComparative Example 2 included 28.22 weight % acrylic resin aqueousdispersion and 7.26 weight % water. The given weight percentages areprovided with respect to the total weight of the combined coatingcomposition.

This example, while not readily yielding under water rubs, when curedfor 72-hours, did show discoloration. As expected, the reactive coatingsbecome more resistant to solvents as they cure. ASTM D5402 was employedin this example to indicate the degree of cure. The coating made withComparative Example 2 stained (effloresced) with cold distilled water.ASTM D1308 was employed to illustrate whether or not the coating wassusceptible to induced efflorescence, which is of great significancewhen applying the coating for decorative purposes, particularly if thecoating were to encounter water in the form of moisture condensation,precipitation, or incidental contact like that from irrigation.

Example 1

The dry mix used in Example 1 included 21.60 weight % Portland Type ICement, 32.40 weight % recycled glass, and 2.80 weight % metakaolin. Thewet mix of Example 1 included 43.20 weight % acrylic resin aqueousdispersion. The given weight percentages are provided with respect tothe total weight of the combined coating composition 112.

The cementitious coating produced using the coating composition 112formed from the components of Example 1 developed rapid film integritywithin 24-hours. This cementitious coating maintained its integrityunder the wet rub test using ASTM D5402 and did not show any signs ofinduced discoloration. ASTM D1308 was performed to illustrate whetherthis cementitious coating was susceptible to induced efflorescence butthe coating did not stain with cold distilled water at ambienttemperature of 25° C.

Example 2

The dry mix used in Example 2 included 24.05 weight % Portland Type ICement, 24.05 weight % recycled glass, 4.81 weight % calcium carbonate,0.67 weight % precipitated amorphous silica, and 3.13 weight %metakaolin. The wet mix of Example 2 included 43.29 weight % acrylicresin aqueous dispersion. The given weight percentages are provided withrespect to the total weight of the combined coating composition 112.

The cementitious coating produced using the coating composition 112 madefrom the components of Example 2 developed rapid film integrity within24-hours. This cementitious coating maintained its integrity under thewet rub test using ASTM D5402 and did not show any signs of induceddiscoloration. ASTM D1308 was performed to illustrate whether thiscementitious coating was susceptible to induced efflorescence but thecoating did not stain with cold distilled water at ambient temperatureof 25° C.

Example 3

The dry mix used in Example 3 included 15.64 weight % Portland Type ICement, 12.08 weight % recycled glass, 1.90 weight % calcium carbonate,0.69 weight % precipitated amorphous silica, 30.96 weight % silica sand,0.95 weight % titania, and 0.25 weight % defoamer. The wet mix ofExample 3 included 0.32 weight % iron oxide pigment, 35.65 weight %acrylic resin aqueous dispersion, and 1.56 weight % fatty acidderivative. The given weight percentages are provided with respect tothe total weight of the combined coating composition 112.

The components of Example 3 were mixed as described above to form thecoating composition 112 which was then used to form the cementitiouscoating. The resultant cementitious coating developed rapid filmintegrity within 6-hours. This cementitious coating maintained itsintegrity under the wet rub test using ASTM D5402 and did not show anysigns of induced discoloration. ASTM D1308 was performed to illustratewhether this cementitious coating was susceptible to inducedefflorescence but the coating did not stain with cold distilled water atambient temperature of 25° C.

Example 4

The dry mix used in Example 4 included 9.16 weight % Portland Type ICement, 9.16 weight % recycled glass, 1.36 weight % talc, 27.47 weight %silica sand, 1.36 weight % titania, 0.14 weight % wetting/dispersingagent, and 0.04 weight % defoamer. The wet mix of Example 4 included0.26 weight % iron oxide pigment, 0.06 weight % thickener, 47.90 weight% acrylic resin aqueous dispersion, 0.24 weight % alkyl silane, 1.22weight % fatty acid derivative, and 1.63 weight % water. The givenweight percentages are provided with respect to the total weight of thecombined coating composition 112.

The components of Example 4 were mixed as described above to form thecoating composition 112 which was then used to form the cementitiouscoating. The resultant cementitious coating developed rapid filmintegrity within 6-hours. This cementitious coating maintained itsintegrity under the wet rub test using ASTM D5402 and did not show anysigns of induced discoloration. ASTM D1308 was performed to illustratewhether this cementitious coating was susceptible to inducedefflorescence but the coating did not stain with cold distilled water atambient temperature of 25° C.

Example 5

The dry mix used in Example 5 included 3.82 weight % Portland Type ICement, 3.82 weight % recycled glass, 1.36 weight % talc, 39.20 weight %silica sand, 3.82 weight % titania, 0.14 weight % wetting/dispersingagent, 0.06 weight % thickener, and 0.06 weight % defoamer. The wet mixof Example 5 included 0.91 weight % iron oxide pigment, 44.86 weight %acrylic resin aqueous dispersion, 0.67 weight % alkyl silane, and 1.28weight % fatty acid derivative. The given weight percentages areprovided with respect to the total weight of the combined coatingcomposition 112.

The components of Example 5 were mixed as described above to form thecoating composition 112 which was then used to form the cementitiouscoating. The resultant cementitious coating developed rapid filmintegrity within 6-hours. This cementitious coating maintained itsintegrity under the wet rub test using ASTM D5402 and did not show anysigns of induced discoloration. ASTM D1308 was performed to illustratewhether this cementitious coating was susceptible to inducedefflorescence but the coating did not stain with cold distilled water atambient temperature of 25° C.

The invention claimed is:
 1. A system for forming a cementitious coatingon a substrate, the system comprising: a first mix comprising a cement,a filler, a defoamer, a cement retarder, a dispersing agent wherein thefirst mix comprises 2.50 wt % to 50.00 wt % cement, 25.00 wt % to 50.00wt % filler, 0.01 wt % to 0.50 wt % defoamer, 0.01 wt % to 0.50 wt %cement retarder, and 0.01 wt % to 1.00 wt % dispersing agent, by weightof the coating composition; a second mix comprising at least one of afatty acid derivative, a synthetic resin, an organosilicon compound, apigment, and a thickener; and a high throughput spraying apparatusconfigured to apply, by spray coating, a coating composition to thesubstrate, wherein the coating composition is formed by mixing the firstand second mix; and wherein the coating has no visible efflorescence andno water rub failure.
 2. The system for forming the coating of claim 1,wherein the substrate comprises pipes, cement, concrete, mortar, glass,metal, wood, drywall, paper, plastics, brick, clay, tile, stone,granite, marble, foam, foam board, slate, terracotta, ceramics, paint,or combinations thereof.
 3. The system for forming the coating of claim1, wherein the high throughput spraying apparatus is selected from thegroup consisting of a high volume low pressure (HVLP) paint sprayer, apiston-pump airless paint sprayer, an air-assisted airless paintsprayer, and combinations thereof.
 4. The system for forming the coatingof claim 1, wherein the high throughput spraying apparatus comprises apiston-pump airless paint sprayer.
 5. The system for forming the coatingof claim 1, wherein the second mix comprises 0.05 wt % to 5.00 wt %fatty acid derivative, 20.0 wt % to 50.0 wt % synthetic resin, 0.01 wt %to 5.00 wt % organosilicon compound, 0.01 wt % to 2.00 wt % pigment, and0.01 wt % to 0.50 wt % thickener, by weight of the coating composition.6. The system for forming the coating of claim 1, wherein the fillercomprises recycled glass, calcium carbonate, talc, precipitatedamorphous silica, silica sand, or a combination thereof.
 7. The systemfor forming the coating of claim 1, wherein the filler comprisesparticles having a particle size of less than 425 micrometers.
 8. Thesystem of forming the coating of claim 1, wherein: the no visibleefflorescence comprises no visible efflorescence when exposed todistilled water at 25° C., as measured according to ASTM D1308; and theno water rub failure is measured according to ASTM D5402.
 9. The systemof forming the coating of claim 1, wherein the fatty acid derivative isat least one material selected from a carboxylic acid group coupled toshort chain carbons having 2-6 carbons, carboxylic acid group coupled tomedium chain carbons having 6-12 carbons, carboxylic acid group coupledto long chain carbons having 13-21 carbons, carboxylic acid groupcoupled to very long chain carbons having more than 21 carbons, oleicacid, stearic acid, calcium stearate, magnesium stearate, aluminumstearate, and zinc stearate.
 10. The system of forming the coating ofclaim 1, wherein the synthetic resin comprises an acrylic resin aqueousdispersion.
 11. The system of forming the coating of claim 1, whereinthe thickener is at least one material selected from clay, cellulosederivatives, galactomannans, microbial polysaccharides, and carboxylatedacrylic copolymer.
 12. The system of forming the coating of claim 1,wherein the organosilicon compound is at least one material selectedfrom siloxanes, polysiloxanes, alkyl or alkoxy silanes having a shortcarbon chain of 2-6 carbons, alkyl or alkoxy silanes having a mediumcarbon chain of 6-12 carbons, alkyl or alkoxy silanes having a longcarbon chain of 13-21 carbons, alkyl or alkoxy silanes having a verylong carbon chain having more than 21 carbons,glycidoxypropylmethyldiethoxysilane, n-octyl triethoxy silane,amino-functional silanes, vinyl-functional silanes, andpolyorganosiloxanes having methyl, ethyl, propyl, cyclohexyl, or phenylgroups.
 13. The system for forming the coating of claim 1, wherein saidsecond mix includes a fatty acid derivative, a synthetic resin, anorganosilicon compound, a pigment, and a thickener.